Maintenance Tips for Hitachi 120 Excavator: Ensuring Optimal Performance

[MikePhua]

The Hitachi 120 series excavator is a popular choice for a range of construction and digging projects, thanks to its reliability, versatility, and performance. However, like all heavy machinery, it requires regular maintenance to keep it running smoothly and to extend its lifespan. This article covers essential maintenance practices, common issues, and tips to ensure your Hitachi 120 continues to perform at its best.
Understanding the Hitachi 120 Excavator
The Hitachi 120 is a part of the well-regarded ZX-1 series, designed primarily for medium-duty construction applications such as trenching, foundation work, and demolition. Equipped with a powerful engine, efficient hydraulics, and advanced electronic systems, the 120 series has become a go-to choice for operators worldwide. However, like any complex machinery, it requires a consistent maintenance schedule to avoid breakdowns and ensure optimal performance.
Key Areas to Focus on During Maintenance

1. Engine and Cooling System
   The engine is the heart of the excavator, so keeping it well-maintained is crucial for performance. Regular oil changes, air filter replacements, and coolant checks should be part of your routine maintenance.
   • Oil and Filters: Regular oil changes are necessary to ensure proper lubrication of engine components. Use the recommended oil type and change it as per the manufacturer's guidelines.
     
   • Coolant System: Ensure that the radiator, hoses, and coolant levels are checked periodically. Overheating can lead to severe engine damage.
     
   • Air Filters: A clogged air filter can reduce engine efficiency. Replace the air filter regularly, especially in dusty environments.
     
2. Hydraulic System
   The hydraulic system in the Hitachi 120 is responsible for powering the boom, arm, and bucket. Hydraulic fluid needs to be checked and replaced regularly to prevent component wear.
   • Hydraulic Oil: Always check the hydraulic oil levels before use, and ensure the oil is free of contaminants. Replace the hydraulic fluid at the recommended intervals to prevent clogging and overheating.
     
   • Hoses and Fittings: Inspect hydraulic hoses for any signs of wear, cracks, or leaks. Damaged hoses can lead to fluid loss and potential hydraulic failure.
     
   • Hydraulic Filter: Replace the hydraulic filter periodically to maintain fluid cleanliness and efficient operation of the system.
     
3. Track and Undercarriage
   Maintaining the tracks and undercarriage is crucial for mobility and the overall performance of the excavator. Worn-out tracks can compromise the machine’s ability to move efficiently, causing delays and potential damage to other components.
   • Track Tension: Check track tension regularly. Too loose or too tight can cause uneven wear and reduce lifespan.
     
   • Track Pads: Inspect the track pads for damage or wear. Replace them when the rubber begins to crack or wear down.
     
   • Rollers and Sprockets: Inspect rollers, sprockets, and idlers for wear. Ensure there is no excessive play in the rollers, which could affect track alignment.
     
4. Brakes and Safety Systems
   Regular inspection of the brake system is essential for safety. This includes checking the brake fluid, testing brake performance, and replacing worn brake pads.
   • Brake Fluid: Ensure brake fluid levels are adequate and the fluid is clean. Low or dirty brake fluid can lead to reduced brake performance and unsafe operating conditions.
     
   • Brake Pads: Inspect the condition of the brake pads and replace them if necessary. Worn-out brake pads can result in reduced braking power.
     
   • Safety Features: Regularly check safety features like lights, horns, and backup alarms. These systems are critical for ensuring operator safety on the job site.
     
5. Electrical System
   The electrical system of the Hitachi 120 controls everything from the engine ignition to the operator cabin’s electrical components. Regular checks are needed to avoid electrical failures.
   • Batteries: Check the battery charge and ensure there are no signs of corrosion on terminals. Clean the battery terminals if necessary to maintain proper contact.
     
   • Wiring: Inspect wiring for damage, corrosion, or wear. A faulty wire can cause electrical malfunctions, leading to equipment failure.
     
   • Fuses and Relays: Regularly check fuses and relays to ensure that the electrical circuits are functioning properly.
     
6. Operator Cabin and Comfort Features
   The operator cabin should be regularly cleaned, and its systems must be checked for proper functioning. A comfortable and well-functioning cabin helps increase productivity and reduces operator fatigue.
   • Air Conditioning: Ensure the air conditioning and heating systems are operational. This will provide a comfortable environment for the operator.
     
   • Seats and Controls: Check for seat and control adjustments to ensure the operator’s comfort and safety. Proper ergonomics reduce fatigue and improve operational efficiency.
     

Common Issues with the Hitachi 120 and How to Resolve Them

1. Hydraulic Leaks: One common issue that many operators face is hydraulic leaks, especially around fittings and hoses. Regular inspections and proper hose maintenance can help detect and address leaks before they cause major problems.
   • Solution: Replace damaged hoses and seals as soon as possible. Tighten fittings that may have loosened over time. Using high-quality hydraulic fluids can also help reduce the risk of leaks.
     
2. Overheating Engine: Overheating is another issue that can arise in heavy machinery, often caused by clogged radiators or low coolant levels.
   • Solution: Regularly clean the radiator and check coolant levels. Ensure there are no obstructions around the cooling system that may impede airflow. If the engine frequently overheats, a professional diagnostic may be needed.
     
3. Track Wear: Tracks are subject to constant friction, which can lead to wear and tear. Uneven wear, damage to track pads, or malfunctioning rollers can affect the performance of the excavator.
   • Solution: Keep the track tension within the recommended range and regularly inspect the undercarriage for wear. Rotate or replace tracks when necessary, and check for debris buildup that can affect track movement.
     
4. Electrical Issues: The electrical system of the excavator is susceptible to issues like blown fuses or faulty wiring, which can affect performance.
   • Solution: Regularly check the electrical components and replace damaged fuses. Inspect the wiring and battery connections to ensure they are clean and secure.
     

Tips for Extending the Life of the Hitachi 120 Excavator

1. Follow the Manufacturer’s Maintenance Schedule: Adhering to the manufacturer’s recommended maintenance schedule is essential for keeping your machine running smoothly and avoiding costly repairs down the line.
   
2. Use High-Quality Parts and Fluids: Always use OEM (Original Equipment Manufacturer) parts and high-quality fluids to ensure the longevity of your equipment.
   
3. Operator Training: Proper training ensures that operators use the excavator efficiently, minimizing wear and tear and reducing the likelihood of breakdowns due to improper use.
   
4. Proper Lubrication: Regularly lubricate moving parts to reduce friction and prevent unnecessary wear.
   
5. Daily Inspections: Conduct daily checks before use, including fluid levels, hose conditions, and any visible damage.
   

Conclusion
The Hitachi 120 excavator is a powerful and reliable piece of equipment, but regular maintenance is crucial to ensure that it operates at peak performance. By staying on top of maintenance tasks like engine checks, hydraulic system inspections, track management, and electrical system upkeep, operators can significantly extend the life of their machine and reduce the likelihood of unexpected breakdowns. Proper care not only enhances the machine's reliability but also improves safety and productivity on the job site.